Preparation of polymerized polyester resin materials of improved strength and water resistance



.ture with a filler.

Patented Mar. 24, 1953 UNITED STATES PATENT OFFICE PREPARATION OF POLYMIERIZED POLYES- TER RESIN MATERIALS OF IMPROVED STRENGTH AND WATER RESISTANCE No Drawing. Application January 31, 1947, Serial No. 725,718

Claims. 1

The invention relates to the preparation of materials of improved strength and water resistance comprising cellulose and a polymerized unsaturated polyester.

A polymerizable unsaturated polyester is highly advantageous as a starting material for the production of hardened synthetic resins in that it isresinous in character before polymerization, and is fusible at a temperature at which polymerization is not rapid. Other heat hardenable compositions, such as urea-formaldehyde and phenolformaldehyde compositions, are much more difiicult to fabricate because they do not exist as plastic resins at temperatures much below their hardening temperatures. A heat hardenable composition can be shaped only while it is in a fused condition, and the failure of other hardenable compositions to reach a fused state below their hardening temperatures is a great handicap in fabricating operations. By the time a hardenable urea-formaldehyde or phenol-formaldehyde product has reached a fused state in a fabricating operation, its hardening already has begun, so that the hardening interferes with the shaping or molding of the composition.

Still other heat hardenable compositions, such as diallyl esters, have low melting points or are liquids at room temperature, but have the disadvantage that they do not attain a resinous state until after hardening has begun. Such compositions cannot be handled satisfactorily in the resinous state that they attain after hardening has begun becausethe hardening, once it has started, is very difficult to stop. Because of the difiiculty of controlling the hardening of compositions such as diallyl esters once the hardening has reached the stage at which the compositions are resinous, such compositions ordinarily are shaped onlyby the casting method, which is the sole method by which they can be handled in non-resinous liquid form.

A polymerizable polyester is resinous because it is a polymer. The resinous state of such a polyester makes it possible to employ the polyester in a molding operation either alone or in admix- A non-resinous liquid composition, such as a diallyl ester, cannot be used in a molding operation because it would be squeezed out of the filler and squirt-ed out of the mold.

A saturatedheat hardenable polyester, such as glycerol phthalate, is hardened by esteriflcation with elimination of water. A polyester that hardens by esteriflcation cannot be employed to make a moldedarticleor other solid body hecause it is too difficult to remove water from the interior of such a solid body in order to complete the hardening. Even urea-formaldehyde and phenol-formaldehyde products .tend to give off small amounts of volatiles as they are hardened in a mold. A polymerizable unsaturated polyester hardens by polymerization without evolution of volatiles.

Among the most useful articles produced from synthetic resins are those in which cellulose is present, usually in the form of a filler or in the form of laminated sheets. The present invention relates to the production of articles containing cellulose and a polymerized unsaturated polyester.

The principal object of the invention is the production of a novel material comprising cellulose and a polymerized unsaturated polyester in which the cellulose is modified so that-the material has greatly improved strength and water resistance. More specific objects and advantages are apparent from the description which merely discloses and illustrates the invention and is not intended to impose limitations upon the claims.

A material embodying the invention, which upon polymerization has improved strength and water resistance, comprises a polymerizable unsaturated polyhydric alcohol-polycarboxylic acid polyester and a material consisting substantially of cellulose, impregnated with a substantially infusible reaction product of formaldehyde and, a substance whose molecule has a plurality of NH2 groups each connected to a carbon atom which in turn is connected by a double bond to an atom selected from the class consisting of nitrogen and oxygen, i. e., an atom of an element whose atomic weight is from 14 to 16. p

The infusible reaction product with which the cellulose is impregnated produces a marked improvement in the properties of the-material ob tained upon polymerization of the polyester. It is believed that the infusible reaction product forms a good bond between the polymerized poly-L ester and the cellulose, so as to increase the strength of the material and to prevent moisture from creeping between the polymeriztd polyester and the cellulose. An important advantage of the presence of the infusible reaction product is that it prevents the strength of the finished material from decreasing appreciably upon soaking of thematerial in water.

In a material embodying. the invention, the cellulose impregnated with the infusible reaction product functions as an inert component, and the polymerizable polyester, functions as a, thermosetting binder for theimpregnated cellulose.

The essence of the present invention is the use of the infusible reaction product as part of the inert component or filler, in combination with the polyester. It was not known heretofore that the combination of a polymerizable polyester with cellulose could be improved by the addition of any other inert substance to the cellulose, and the present invention is based upon the discovery that an important improvement is produced by the use of the infusible reaction product hereinbefore described as part of the inert component or filler with which the polymerizable polyester is used as a thermosetting binder.

A molding composition embodying the invention comprising a polymerizable polyester, and cellulose impregnated with an infusible reaction product hereinbefore described, such as a ureaformaldehyde reaction product, is quite different from a molding composition in which such reaction product is still fusible and therefore constitutes part of the thermosetting binder rather than part of the inert filler. In the latter composition the thermosetting binder is made up of both the polymerizable polyester and the thermosetting urea-formaldehyde reaction product. The latter composition is highly unsatisfactory because the therlnosetting polyester and the thermosetting urea-formaldehyde reaction product do not set at the same time. At ordinary temperatures, such a composition soon becomes so stiff as to be worthless for molding, because the polyester is acid and its acidity causes the urea-formaldehyde reaction product to set to an infusible resin which rigidifies the composition even though the polyester remains fusible. At molding temperatures the polyester sets much faster than the urea-formaldehyde reaction product. Thus in a hotmolding operation such a composition is too stiff at first because the urea-formaldehyde reaction product has not yet fused. By the time the urea-formaldehyde reaction product has fused, the polyester already has set to rigidify the composition. A molding composition embodying the invention gives entirely diiferent results, by reason of the fact that the reaction product with which the cellulose is impregnated is in an infusible state. The infusible reaction product functions as a part of the inert filler to give the novel and'advantageous results hereinbefore described.

The material consisting substantially of cellu-' lose that is used in the practice of theinvention may be any one of a number of well-known materials such as alpha cellulose, wood flour, wood pulp, sawdust, wood shavings, walnut shell flour, chopped newspapers or ground corn cobs. In a molding composition embodying the invention the cellulosic material may be finely divided or it may include relatively large pieces of chopped cotton cloth to give maximum impact strength.

When the present invention is used to produce a sheet of paper coated with a polyester, the impregnated cellulosic material is in the form of a single sheet. Sheets of cellulosic cloth or paper impregnated with'the substantially infusible reaction product may be bonded into a laminate by a polymerized polyester resin.

Under the proper conditions, impregnation of the cellulosic material with one of the reaction products hereinbefore described may be achieved by mixing the cellulosic material with a solution of a soluble form of the reaction product in a polymerizable polyester. However, it .hasbeen found preferable to employ an aqueous solution of the reaction product for impregnating the cellulosic material. The cellulosic material can be mixed with an emulsion of the polyester in an aqueous solution of the reaction product. In any case the cellulosic material cannot be impregnated with the polyester before it is impregnated with the reaction product, because previous impregnation with the polyester would prevent the cellulosic material from being impregnated with the reaction product.

The preferred procedure is to impregnate the cellulosic material with a solution of a reaction product of formaldehyde and one of the substances hereinbefore described before the cellulosic material is incorporated with the polyester.

Ordinarily it is preferable also to convert the reaction product substantially to its infusible state before the impregnated cellulosic material is mixed with the polyester. If a cellulosic filler impregnated with a fusible reaction product of the type hereinbefore described is mixed with a polymerizable polyester, the acidity of the polyester thereafter causes the reaction product to be converted into its infusible state. The infusible reaction products thus produced is in the form of' a molecular network that extends throughout the composition and may render the whole composition quite stiff and infusible. In order to obtain a moldable material, it then may be necessary to grind up the composition or otherwise rework it to break down the molecular network formed by the infusible reaction product.

In the production of laminates or single sheets of impregnated paper in accordance with the invention, it may not be necessary to convert the reaction product to its infusible state before the sheets are incorporated with the polyester, and the conversion of the reaction product to its infusible state may take place simultaneously with the polymerization of the polyester.

In the practice of the invention, the cellulosic material may be impregnated with a reaction product of formaldehyde and a substance whose molecule has a plurality of NH2 groups each connected to a carbon atom which in turn is connected by a double bond to an atom selected from the class consisting of nitrogen and oxygen, e. g. urea; a guanazole such as guanazo'le,

NH,0=N

NH N=o NHz or l-carbamyl gu'anazol'e,

NH2C=N O N- t'-Nm N=o NHi a diurea such as ethylene diurea,

a dicarbamate such as diethylene glycol dicarbamate,

I ll Nmbeo omomo QHzC 112-0 o-Nn;

afpyrimidine such as 2,4-diamino-6-hydroxy pyrimidine,

on-o-mi:

HO-O

N=-NH= or a quinazoline such as 2,4-diaminoquinazoline,

\HC N/ Exceptionally good results are obtained when the substance reacted with formaldehyde is one whose molecule has a plurality of NH2 groups each attached to a triazine ring, e. g. melamine; a guanamine such as formoguanamine,

or a diguanamine such as adipoguanamine,

or sebacoguanamine, Y

' C\-(CH2)s-/-C i i i Nz \N/ NHz Nz \N/ V\NH2 The substance whose reaction product with formaldehyde is employed preferably has a molecule containing no atoms other than carbon, nitrogen, hydrogen and oxygen.

In the preparation of a reaction product for use in the practice of the invention, one of the substances hereinbefore described, for example,

melamine or urea, or a mixture thereof, may

be reacted either with formaldehyde or with a polymer thereof, such as paraformaldehyde. Preferably, the substance is reacted with a solu- "-tion of formaldehyde in water, in an organic solvent such as an alcohol, or in a liquid conintermediate alkylated reaction product may be obtained that is soluble in a polyester. The

reaction may be performed in an autoclave, ii":

desired, to secure a reaction temperature above 6 the boiling point of the solvent. When an aqueous formaldehyde solution is used for the reaction, the solution preferably is about neutral at the start of the reaction. Since a commercial aqueous formaldehyde solution is strongly acid, a base preferably is added to bring the initial pH of the reaction solution to the desired value; Any desired base'may be employed. The preferred proportions are about 3 mols of. formaldehyde for every 2 mols of urea and about 3 mols of formaldehyde for each mol of melamine. The maximum amount of formaldehyde that will react is approximately 2 mols for each mol of urea and approximately 6 mols for each mol of melamine, but an excess of formaldehyde above these maxima, or any smaller proportion ranging down to one mol of formaldehyde for each mol of urea or melamine, may be used for the reaction if desired. Because of the complexity of the molecules of the reaction products that are produced, the proportion of formaldehyde actually reacting with the melamine or urea may vary freely between the limits stated.

Any other of the aforementioned substances, or mixtures thereof, may be reacted with for: maldehyde in substantially the same manner to produce reaction products for use in the practice of the invention.

Examples of molal ratios of formaldehyde to such substances in the reaction products are 2:1 for guanazole or l-carbamyl guanazole, 2:1 for ethylene diurea or propylene diurea, 2.5:1 for diethylene glycol dicarbamate, 4:1 for 2,4-diamino-G-hydroxy pyrimidine, 3:1 for 2,4-diamino quinazoline, 2:1 for formoguanamine, acetoguanamine or benzoguanamine and 5:1 for adipoguan amine or sebacoguanamine. The reaction proceeds at normal temperatures, but heating ordinarily is desirable to shorten the time of reaction or, in some cases, to dissolve the substance to be reacted with formaldehyde. A solution for impregnating the cellulosic material may be prepared by carrying the reaction only to its earliest stage, for example, the stage at which the reacting ingredients have just dis-E solved to form a solution, or by carrying the reaction to any further stage (short of the-insoluble stage). V 7

By advancing the reaction, it is possible to obtain intermediate reaction products that are insoluble but still fusible. Intermediate reaction products so prepared can be milled with the cellulosic material on'a heated two-roll (differential speed) rubber mill in order to impregnate the cellulosic material thoroughly before conver sion of the reaction products to a substantially infusible resin. However, for the purposesof the inventionl'it is convenient to employ the soluble types of intermediate reaction products. In the preparation of a fillerfor a molding composition embodying the invention the cellulosic material may be impregnated with an aqueous solution of the reaction product and then dried. The dried, im pregnated cellulosic material may be ground to a fine powder, in a ball mill, for example, in order to produce a homogeneous composition. -An acid substance may be incorporated during the grinding stage; The fine powderso obtained may be baked to convert the reaction product to a substantially infusible form. Molding scrap or waste which consists essentially of cellulosic material impregnated with an 'infusible' reaction product of the class described may be-ground and used in the preparation of a molding compoundof the instant invention. Such waste material is .very dense and therefore must be ground to afine powder before it can be used as a filler, although it is difiicult to grind.

In the preferred method of preparing a filler for a molding composition embodying the invention, the cellulosicmaterial is impregnated, in ashredder, for example, with an aqueous solution of thereaction product, an acid substance is incorporated, and then the material is dried. The dried impregnated cellulosic material thus produced is relatively brittle and need not be ground before incorporation with the polyester binder. However, it may be desirable to grind the. material, in a ball mill, for example, in order .to incorporate a polymerization catalyst for. the polyester binder or to produce a more homogeneous final molded product.

Another aspect of the invention is based upon the discovery that the moisture resistance of finished molded articles embodying the invention is noticeably superior if the impregnated cellulosic material is not ground after the reaction product has been converted to the infusible state. Therefore the omission of grinding is generally preferred. Although the reason for this phenomenon is not completely understood, it is believed that one of the functions of the reaction product is to form a hard impenetrable casing around the cellulose particles, and that grinding to some extent cracks or loosens this casing.

The proportion of the infusible reaction product to the cellulosic filler may range from a very small proportion such as about 1 part of reaction product to parts of cellulosic filler to a very high proportion such as 10 parts of reaction product to about 1 part of cellulosic filler. (The terms parts and per cent, as used herein to refer to quantities of material, mean parts and per cent by weight.) The preferred ranges depend upon the particular reaction product employed. For example, the range for the per cent of melamine-formaldehyde reaction product in the dried, impregnated cellulosic filler in which the beneficial effects of the invention are particularly apparent may be from about to about per cent, and the optimum per cent at which the best all-around combination of properties is obtained for the amount of the reaction product used, may be about 40. On the other hand, in the caseof a urea-formaldehyde reaction product, the preferred range may be from about 50 to about 80 per cent and the best results may be obtained at about '65 percent.

In the preferred method of preparing impregnated cellulosic sheets for use in a laminate embodying the invention, a cellulosic cloth or paper is dipped in an aqueous solution of the reaction product and then dried, preferably at an elevated temperature in order to convert the reaction product to a substantially infusible state. As a practical matter in an industrial application, pulp in a paper machine may be pretreated by the manufacturer so as to produce paper sheets already impregnated with a substantially infusible reaction product. Other methods of impregnating cellulosic laminating materials, such as spraying or brushing an aqueousor organic solvent solution of the intermediate reaction product onto the material, may also be employed.

The proportion of the infusible reaction'product to the cellulosic laminating material may range form as low as about 1. part to 200,,at

which some :of the benefits of the .invention may be obtained without "appreciably afiecting. the original flexibility of the laminating material, to as much as about one part of reaction product to each part of filler, which is about as much reaction product as may be used while still retaining the general characteristics of the cloth or paper in the laminating material. Small amounts of reaction products produce a more noticeable beneficial effect in laminates than corresponding amounts in molded products. The preferred ranges depend upon the type of laminating material used. For example, in the case of laminating paper the preferred range may be from about 2 to about 20 per cent of the reaction product in the dried, impregnated paper, and about 10 per cent may be the optimum at which the best all-around results are obtained. On the other hand, in the case of cellulosic cloth, such as muslin, the preferred range may be from about 5 to about 35 per cent and the best all-around results may be obtained at about 25 per cent.

The polymerizable unsaturated polyhydric alcohol-polycarboxylic acid polyester used in the practice of the invention is prepared by reaction of one or more polyhydric alcohols and one or more polybasic acids. The proportion of polyhydric alcohols having more than two hydroxy groups, such as glycerol or pentaerythritol, and the proportion of polycarboxylic acids having more than two carboxy groups, such as citric acid, preferably is small so that in the production of the polyester there may be maximum esterification of the hydroxy and carboxy groups without attainment of excessive viscosity. Ordinarily it is desirable that the unsaturated polyester be polymerizable into an infusible or high melting point resin, so that the proportion of unsaturated components should be such that the polyester contains an average of more than one double bond per molecule; for example, there may be an average of eleven or more double bonds in every ten molecules of the polyester.

The present invention is equally applicable to all polymerizable unsaturated polyhydric alcoholpolycarboxylic acid polyesters. A typical example of such a polyester is a product prepared by the reaction of an unsaturated dicarboxylic acid such as maleic, fumaric, itaconic, citraconic or mesaconic acid with a dihydric alcohol such as any polymethylene glycol in the series from ethylene glycol to decamethylene glycol, propylene glycol, any butylene glycol, any polyethylene glycol in the series from diethylene glycol to nonaethylene glycol, dipropylene glycol, any glycerol monobasic acid monoester (in either the alpha or beta position), such as monoformin or monoacetin, any monoether of glycerol with a monohydric alcohol, such as monomethylin or inoncethylin, or any dihydroxy alkane in which the hydroxy radicals are attached to carbon atoms that are primary or secondary or both, in the series from dihydroxy butane to dihydroxy decane.

Part of the unsaturated dicarboxylic acid may be replaced by a saturated dicarboxylic acid, such as any normal acid in the series from oxalic acid and malonic acid to sebacic acid, or any benzene dicarboxylic, naphthalene dicarboxylic or cyclohexane dicarboxylic acid, or diglycolic, dilactic or resorcinol diacetic acid. All of the unsaturated acid may be replaced by a saturated acid if a polyhydric alcohol is present whose molecule has two or three free hydroxy groups and consists of an ether of one or two molecules of allyl or methallyl alcohol with one molecule of 1a polyhydroxy com- 'the polyester. 1y equal the molecular proportions of dibasic acid and dihydric alcohol, the greater is the average number of residues in the resulting polyester pound such as glycerol, pentaglycerol, pentaerythritol, butantetrol-1,2,3,4, a trihydroxy jnormal alkane having from four to five carbon atoms such as butantriol-1,2,3 or a, mono-alkyl ether of pentaerythritol or butantetrol-1,2,3',4 in which the alkyl radical has from one to four carbon atoms and has from one to two hydrogen atoms attached to the same carbon atom as the ether linkage, such as the monomethyl or monois'obutyl ether of pentaerythritol.

In the preparation of the polymerizable unsaturated polyester, any of the usual modifiers such as monobasic acids, monohydric alcohols and natural resin-acids may be added. The larger the proportions of monobasic acids and monohydric alcohols, thelower is the average number of acid and alcohol residues in the resulting polyester molecules, and the lower is the viscosity of On the other hand, the more nearmolecules, and the greater is the viscosity. The proportions of ingredients used are those proportions that produce a polymerizable polyester of the desired viscosity. Other properties of the polyester, such as solubility in various solvents,

also may be varied by selecting various reacting ingredients and varying their proportions. The

infusibility, hardness and inertness of the product obtained by polymerization of the polyester may be increased by varying the initial reacting ingredients to increase the average number of double bonds per molecule of the polymerizable polyester. The point to which the reaction of the ingredi- "ents is carried in the preparation of the polymerizable polyester is simply that point at which the product has the desired consistency. The consistency or viscosity of the polyester varies directly with the average number of acid and alcohol residues in the molecule. For example, the average number'of residues in the molecule of the "polyester may vary from about three to about one hundred twenty.

If desired, the reaction may be expedited by use of an acid substance as a catalyst.

acid, inorganic acidor acid salt that is soluble in the reaction mixture may be employed as a catalyst, but it is desirable that any acid substance used be readily volatile or be of sucha character that it has no deleterious effect in the finalproduct. The amount of acid catalyst employed is simply that amount which accelerates the esterification to the desired degree.

The reaction is carried out at a temperature high enough and for a time long enough to secure the desired consistency. An elevated temperature preferably is employed to expediate the reaction,

but duringthe preparation or the polyester, the temperature should not be so high nor the time of reaction so long as to cause substantial polymerization. There is less danger of premature polymerization if an inhibiting agent is added before the esterification is carried out.

Whenever added, an inhibiting agent is used in the proportion required to give the desired degree of inhibiting effect. use difierent inhibitors in widely difierent proportions in order to secure the same inhibiting efiect.

It may be necessary to Any desired anti-oxidant such as hydroquinone, pyrogallol, tannic acid or any aromatic amine, such as aniline or phenylene diamine may be employed as an inhibitor.

The preparation of the unsaturated polyester Any organic tinued for 6% hours. a moderately stiif liquid having an acid number .of 11.

vated temperatures used.

The acid number of the product depends upon the degree of reaction and the proportions of acid and alcohol used for the reaction. With equimolecular proportions of dibasic acid and dihydric alcohol, the reaction may be carried to an acid number of about 20. The use of an acid catalyst may make it possible to attain a lower acid number without substantial polymerization.

A polymerizable polyester-may be prepared by the following procedure:

A three-necked flask is employed in which 5.4 mols of maleic anhydride and 5.4 mols of diethylene glycol are mixed together. The flask is then fitted with a thermometer, a tube leading to a condenser and an inlet tube through which is introduced a moderate stream of carbon dioxide, and is lowered into an oil bath at a temperature of 210 C. During the subsequent reaction the distillate may be analyzed, and a sufficient amount of the ingredient lost in excess may be added to the flask from time to time to maintain the initial proportions of reacting ingredients. If the only addition is a sufficient amount of the ingredient lost in excess to maintain the initial proportions, the rate of removal of unreacted ingredients gradually decreases and substantially no unreacted ingredients may be left in the composition at the end of the reaction. After 8 hours at such temperature, a polyester is obtained in the form of a stiff liquid having an acid number of 18.

If ethylene glycol were substituted for the diethylene glycol in the foregoing procedure, it would be diflicult to reduce the acid number below 40 without causing polymerization, and the j product would be a very thick gum.

Alternatively, this first procedure, as described in the foregoing paragraph, may be employed except that 1.5 instead of 5.4 mols of maleic anhydride and 1.5 instead of 5.4 mols of diethylene glycol are used together with an amount of hyjdroquinone equal to 0.2 per cent of the weight of the reacting ingredients; and reaction is con- The resulting polyester is A further procedure that may be used is the same as the first procedure except that 2 instead of 5.4 mols of maleic anhydride and 2.1 instead of 5.4 mols of diethylene glycol are used;

and the reaction is carried out for 4% hours toproduce a stifi liquid having an acid number of 14.

Another type of polymerizable polyester may be prepared by a procedure that is the same as the first procedure except that 3 instead of 5.4 -mols of maleic anhydride and-3.3 instead of 5.4

mols of diethylene glycol are used together with an amount of hydroquinone equal to .09 per cent of the weight of the reacting ingredients and an amount of p-toluene sulfonic acid equal to 0.18 per cent of the weight of the reacting ingredients; and the reaction is carried out for four hours at 200 C. to producers. stifi liquid having an acid number of 10.6.

As a further alternative, the first procedure may be employed except that the amount of maleic anhydride employed is 6 insteadof 5.4 mols; the diethylene glycol is replaced by 6 mols of ethylene glycol; a slower stream of carbon dioxide is used; and the ingredients are kept in an oil bath at 220 C. for hours. The resulting polyester is a very thick gum having an acid number of 53.

A polymerizable polyester may also be prepared by a procedure that is the same as in the preceding paragraph except that the maleic anhydride is replaced by 5 mols of fumaric acid; the ethylene glycol is replaced by 5 mols of diethylene glycol; and the reaction is continued for 8% hours. The resulting polyester is a stiff liquid having an acid number of 23. If in the foregoing procedure the diethylene glycol and half of the fumaric acid were replaced by an equimolecular proportion of phthalic anhydride, the product would be a hard brittle solid. The substitution of fumaric acid for maleic anhydride increases the length of time required to reach a given acid number at a given temperature. However, the accelerating effect of an acid catalyst upon the esterification is greater when fumaric acid is used. When fumaric acid is employed, other conditions being the same, the resulting polyester tends to be more viscous and greater care is necessary in order to prevent premature polymerization.

As a further variation, the first procedure may be used except that the maleic anhydride is replaced by 15 mols of fumaric acid; the amount of diethylene glycol employed is 1.5 instead of 5.4 mols; and the temperature is varied between 200' and 220 C. After the reaction has been continued for 2 hours, the acid number is 73. After 6 hours, the product is a stiff liquid having an acid number of 41.

A polymerizable polyester may also be prepared by a procedure that is the same as that of the preceding paragraph except that p-toluene sulfonic acid (1.5 grams is added to the initial ingredients; and reaction for only 2 hours instead of 6 hours is required to produce a stiff liquid having an acid number of 41.

A procedure that may also be used is the same as that of the next to the last paragraph except that the fumaric acid is replaced by 3.3 mols of maleic anhydride; the amount of diethylene glycol used is 3.0 instead of 1.5 mols; 1.5 grams of p-toluene sulfonic acid and 1.3, grams of hydroquinone are added, to the initial ingredients; and the reaction is carried out for 3 hours to produce a limpid liquid having an acid number of 26.

A polymeriza'ble polyester maybe prepared by a procedure that is the same as the next to the last paragraph except that 3 instead of 1.5 mols of fumaric acid and 3.3 instead of 1.5 mols of diethylene glycol are used; and the reaction is carried out for 3 hours at temperatures ranging from 200-210 C. to produce a stifi liquid having an acid number of 12.

A further procedure that may be used is the same as that of the next to the last paragraph except that the hydroquinone is omitted; and

reaction for 5 hours is required to produce a stiff liquid having an acid number of 28.

Another procedure that may be used is the same as the procedure of the next to the last paragraph except that the weight of p-toluene sulfonic acid is-equalto 0.18 per cent of-the weight of the reacting ingredients; anamount of .hydroquinone equal to 0.09 per cent of the weight of the reacting ingredients is added at the start of the reaction; and reaction is carried out at 200 C. for 5 hours to produce a stifi liquid which has an acid number of 10.1.

Polymerization of these materials usually is carried out at temperatures of about 160 to about 180 F. A solution comprising one or more polymerizable unsaturated polyesters and one or more polymerizable monomeric compounds is particularly useful as a binder. Either the unsaturated polyester or the. monomeric compound or both may be partially polymerized before the ingredients are mixed. Polymerizable monomeric compounds that are useful for the-preparation of such a solution include diallyl phthalate, diallyl oxalate, diallyl diglycolate, triallyl citrate, carbonyl bis-(allyl lactate), maleyl bis-(allyl lactate), fumaryl bis-(allyl. lactate), succinyl bis- (allyllactate), adipyl bis-(allyl lactate), sebacyl bis-(allyl lactate), phthalyl bis-(allyl lactate), Iumaryl bis-(allyl vglycolate), carbonyl bis-(allyl glycolate), carbonyl bis-(allyl salicylate), tetra- (allyl glycolate) silicate, and tetra-(allyl lactate) silicate.

Such a solution, which usually contains, about 20 to 30 per cent of the polymerizable monomeric compound and about 70 to per cent of the polymerizable polyester, is particularly advantageous because the polyester has desirable physical properties and hardens very rapidly whereas the presence. of the monomeric compound causes the polymerized product to be much more water resistant and insoluble. Moreover, the combination of the polyester and the monomeric compound usually polymerizes more rapidly than eitherof such substances alone.

A similar solution may be prepared by dissolving the polyester, before use, in a polymerizalole substance such as styrene, vinyl acetate,

methylmethacrylate or methylacrylate.

In the production of a molding compound embodying the invention the mixing of the dried impregnated cellulosic filler with the polymerizable polyester may be carried out by any of the known methods. .If the polyester is very viscous, .it may be necessary to incorporate the cellulosic filler in the polyester on a heated tworoll (difierential speed) rubber mill or it. may be desirable to heat the polyester in order to reduce the viscosity sufiiciently to permit the use of other mixing procedures. Ordinarily the viscosity of the polyester is such that kneading or equivalent mixing procedures may be used satisfactorily. In some cases itmay be desirable to dilute the polyester with a solvent in order to facilitate mixing with the cellulosic filler.

The proportion of the impregnated cellulosic .filler in a molding composition embodying the invention may. range from a very small propor-- tion such as about 1 per cent to a very high proportion such as about 80 per cent. The compositions containing very small amounts of cellulosic .filler are usually special compositions in which a mixed filler of cellulosic material and another material is employed. It may be desirable to use a mixed filler of cellulosic material and another material in a cold molding composition, for example, in which the per cent total. filler in the composition may be as high as per cent. Generally speaking, the preferred range is from about 40 to about 75 per cent of impregnated cellulosic filler in the molding composition, and the best Casting and adhesive compositions embodying the invention, of course, may contain as little as l per cent of impregnated cellulosic filler, and the maximum per cent of filler in such compositions is simply that tmount which may be added to the polyester without rendering the compsitions too stiff. For example, in adhesive compositions the proportion of the filler to the polyester may range from as low as about 1:100 to as high as about 1:4, the preferred proportions being from about 1 :30 to about 1 :5.

Since the polymerizable polyester is fusible and plastic at relatively low temperatures, it is possible to adjust the amounts of catalyst and inhibiting agent so that the hardening at such temperatures takes place at a reasonable rate to allow ample opportunity for shaping and molding of the composition. In this manner compositions may be produced which are fast curing, gas free and'adapted to complicated moldings (e. g. clock cases) The preferred catalyst for use in the practice of the invention is benzoyl peroxide, but any other organic peroxide such as suocinyl peroxide, acetyl peroxide, peracetic acid, perbenzoic acid, toluyl peroxide, p-brombenzoyl peroxide, anisoyl peroxide, chloroacetyl peroxide or furoyl peroxide, or any organic ozonide, such as diisopropylene ozonide or diisobutylene ozonide, or a mixture of such substances, may be used as the curing catalyst.

The proportion of the curing catalyst is simply the proportion that causes the composition to polymerize at the desired rate. The proportion of curing catalyst varies with different catalysts.

The proportion ofcuring catalyst employed to same rate as a similar polyester prepared from fumaric acid and diethylene gylcol in which the proportion of benzoyl peroxide is about 0.5 per cent.

If the binder used in the practice of the invention comprises a viscous-polymerizable substance and a less viscous polymerizable substance, the polymerization catalyst may be-dissolved in the less viscous polymeriaable substance before the two substances are mixed. On the other For example, a polyester prepared hand, it is often desirable to disperse the polymerization catalyst in the cellulosic filler by grinding with the filler in a ball mill, for example, before the filler is mixed with the polyester. In some cases a fibrous filler may be mixed with a solution, in a volatile solvent, of the polymerization catalyst and dried before the filler is mixed with the polyester. is carried out in the production of a molding or casting composition, plasticizers, lubricants, pigments and other coloring matter may be incorporated if desired.

The magnitude of the improvement in the strength and water resistance of molded articles attained in the practice of the invention may be demonstrated by tests carried out as follows: A solution of '1 mol of melamine in formalin (37 per cent aqueous formaldehyde solution) containing 3 mols of formaldehyde is held at 80 C. for 10 minutes at a pH of 7. A cellulosic filler is When the present method; j

completely impregnated by mixing it in an egg-r beater type mixer with the resulting solution of a melamine-formaldehyde condensation product diluted with sufiicient water so that the weight of the diluted solution is from two to three times the weight of the cellulosic filler. The impregnated .filler is then thoroughly dried and the melamine-formaldehyde condensation product is converted to a substantially infusible state by heating at 180 to 190 F. for 72 hours. A polymerizable polyester is prepared by the procedure hereinbefore described from a charge consisting of 1.05 mols of monoethylene glycol, 1 mol of maleic anhydride and an amout of hydroquinone equal to 0.04 per cent of the charge. The charge is heated to 2 20" C. (over a period of two hours) and is held between 220 C. and 226 C. for six more hours. The resulting polyester parts), which has an acid number of about 35, is cooled to -150 F. and is thoroughly mixed with diallyl phthalate ('5 parts) and a paste of benzoyl peroxide as a catalyst (1.5 parts) and tricresyl phosphate (1.5 parts) to form a solution. The impregnated cellulosic filler, the polymerizable polyester solution and, as a lubricant, an amount of zinc stearate equal to 2 per cent of the composition are then milled for 10-12 minutes on a heated two-roll (differential speed) rubber mill at the lowest temperature at which a homogeneous mass can be obtained. The resulting composition is removed in sheets, is allowed to solidify fully while at about 80-90 F., and then is granulated in a high speed cutter to a maximum particle diameter of about inch. The granulated composition is compression molded to produce articles of dimensions suitable for physical testing. The composition is fast curing and gives moldings free from gas. I

Table 1 shows the results of strength tests of 4), and by specifying whether or not the dried impregnated filler is ground in a ball mill before mixing with the polyester (col. 3). For the sake of comparison, test data for control articles,i.e.,

articles in which the reaction product is omitted from the cellulosic filler, are included in Table l.

The strength tests employed are standard tests for plastic materials and are considered to be capable of showing generally the strength characteristics that are important in industrial plastic materials of this class. A separate description of the procedure and results of each test follows:

Flexural strength (col. 5)-A small bar /z" X /8" x 5"), molded of the material to be tested for three minutes under a pressure of 5,000 lbs. per square inch in a mold heated with steam at 60 lbs. gauge pressure, is supported at its extremities and a transverse load is applied :centrally. The flexural strength S is the extreme fiber stress in pounds per square inch at which the bar fails, calculated according to the formula in which to is the load in pounds, 1 is the length in inches of the bar or span between the supports, I) is the horizontal dimension in inches otthecross se'ctio'nnfithe banand'misthevertical dimensionzinjnchessofrthe cross section of the.

bar. From Table. 1 ,it' canxbe seenthat the articles embodying the invention have from 45. to 80 per; cent more flexural strength .than the control articles.

Deflection (col- 6)The deflection of the bar used in the flexural strength test is measured at the instant the bar fails. The elastic modulus (inflexure) may be calculated from Youngs formula' pressure of 17,000 lbs. per square inch in a mold heated with steam at '75 lbs. gauge pressure. Standard Barcol hardness apparatus is em.-

ployed and hardnessis. read from .a: dial gauge" which gives hardness readings as compared to anarbitrary standard- From Table 1 it can be in'1Which.Misthemodullls inspoundsper square 15 seen that the articles embodying the invention inch; mg (mass times gravity) is the loadin have as much as 25.to 40 percent greater hardpounds, 1 is the length in inches; of the bar or ness than the control articles. i

" TABLE 1 Percent Percent Barcol 4 Flexural Defiect. Compress. Impact Type M191 gggg Ground 36 32; Strength Strength Strength Strength gg? oen. Powder 0 No 00 7, 190 0. 072 23, 050 as Do N0 50 0, 440 0.080 075 0. 24 41 20 No 00 12, 370 o. 105 33,800 0. 37 40 Yes 55 10, 800 0. 109 32, 500 0. 3a 49 Yes 55 12, 710 0. 12s 35, 575 0v s1 47 40 Yes 55 13, 050 0.125 as, 700 0. a4 54 00 Yes 55 11, 700 0. 154 3a, 350 0. 20 45 0 No 55 8,800 0. 071 27, 100 0. s5 40 10 No 55 12, 420 0.105 31, 550 0. s4 47 20 Ne 55- 11, 240 0. 090 20, 950 0. 40 45 40 No 55 11, 870 0. 103 as, 725 0. 45 57 span between the supports, 3 is the deflection in The results given in Table 2 show the improved inches, at is the vertical dimension in inches of water resistance of articles embodying the inthe cross section of the bar and his thehorizon- 35 vention as compared to control articles, 1. e.-, tal, dimension in inchesof the cross section of articles in which the reaction product is omitted the bar. From Table 1 it can be seen that the from the cellulosic filler. Water resistance vararticles embodying the invention are capable of ies with the amount of moisture that an article undergoing asmuch as 65 to '75 per cent greater is capable of absorbing because the degree of deflection thanithe control articles. 40 deterioration upon exposure to moisture varies Compressivestrength (col. 7)--A small bar with the amount of moisture absorbed. xi x 1") molded under the same condi- The test piece for determination of water abtions is subjected to a compressive force acting s ption is the disk above described which We hs longitudinally until the bar crumbles or-shatters. 6.5 grams. The disk is immersed in water for The-compressive strength is the force F in pounds 43 a ive p od Of e} and the Water absorption per square inch at which the bar fails, calculated is measured as the g in Weight (in ams) according to the formula durmg immersion.

144w In Table 2, columns 1, 2, 3 and 4 give the same F: b information as the corresponding columns in a 50 Table 1. The Water absorption is given for tests inwhich w is the. load in pounds and a and b are in which test pieces made from the various moldthe dimensions in inches of the cross section .of ing compositions are immersed. in .cold water the bar. From Table l itcan be seen that the for'24 hours (col. 5) or? days (col. 6), or in articles-embodyingthe invention have compres boiling water for 1 hour (col. 7).

TABLE 2 Abs. in Abs. in Abs. in Percent Percent Ty'peot Filler 0nd Ground Filler 5& g g eggg Product in Comp. 1 7 days: 1

0 No 00 028 0.54 0.25 5 N0 00 0. 105 0. 505 0. 20' N0 60 O. 055 0. 25 0. 135 10 Yes 55 0. 10 0.525 0. 2a 20 Yes 55 0. 115 0. 0.17 Yes 55 0. 04 0. 13 0. 105 00 Yes 55 0. 03 0. 07 0. 07 0 No 55 0. 225 0.475 0.15 10 No 55 0.135 0. 0.11 20 No 0. 07 0. 2s 0.115 40 No i 55 0. 03' o. 095 0. 055

From Table 2.it can-be seen that the control articles in the cold water test absorb from 5 to '7 times as much water in 24 hours and from 3 to 5 times as much Waterin '7 days as the articles embodying the invention. In the boiling water gauge readingis obtained which represents the test the control articles absorb from 2 to 3 times '17 as muchwater as the articles embodying the invention. 1

Tables 1' and 2 show that, although grinding the impregnated cellulose after the reaction product has been converted to the substantially 5 'infusible state does not appreciably affect the strength, the omission of this step further reduces the water absorption by 25 to 35 per cent in the molded articles embodying the invention. Also, it has been discovered that increasing the per centof allyl monomer (e. g. diallyl phthalate) in the polymerizable polyester from 5 per cent to per cent reduces the water absorption by as much as 50 per cent. 1 c

Stability of the molding composition is determined by molding samples of the composition before and after aging at room temperature for agiven period of time, using a standard cup mold at a temperature corresponding to 60 pounds gauge pressure of steam. The pressure required to produce the molded cup is used as a measure of the fusibility of the composition -,a nd,jin general, the stability may be considered -to be inversely proportional to the increase in the required pressure upon aging. The stability of the compositions embodying the invention is not appreciably different from that of the control. compositions, and the results of stability tests indicate that the impregnation of the cellulosic fillers does not impair the stability of the molding compositions. It the cellulosic filler is impregnated with a reaction product of formaldehyde and one of the substances hereinbefore described other than melamine, a noticeable improvement in strength and water resistance is also shown. Such an .improvement is shown, for example, when a molding composition is prepared and tested by a procedure that is the ame as the procedure just described, except thatthe melamine is replaced by 2 mols of urea, and the solution is held at 30 C. for 390 minutes and then is brought to a pH between 5.5 and 6.0 by addition of lactic acid. The molding composition so pre- -.pared appears to be fast curing and free from gas. The strength of pieces molded from this composition is shown in Table 3, which corresponds to Table 1, and the water absorption is shown in Table 4, which corresponds to Table From the tables it can be seen that the articles embodying the invention in which-the ureaformaldehyde reaction product is used show improvements in fiexural strength of as much as 510 per cent, in deflection of as much as 100 per cent, in compressive strength of as much as 10 per cent and in hardness of as much as-20 per cent as compared with the control articles; In the water absorption tests the control articles when immersed in cold water absorb 5 times as much water in 245 hours,.and 3 times as much I water in 7 days a as the articles embodying the invention. While these data show verygreat improvements itis-apparent that thedata for the compositions containing melamine-formaldehyde impregnated fillersshow even greater iniprovements. 1 t In general, reaction products of formaldehyde with most of the substances hereinbe'fore described give results similar to those obtained with a urea-formaldehyde reaction product, but the compounds whose molecules have a plurality of NI-Iz groups each connected to a triazine ring, such as benzoguanamine, perform more like melamine, which gives outstandingly goodresults in the practice of the invention. Although the reasons for such results must logically be at tributed to the presence of the triazinering, the exact function of the triazine ring is not understood, nor is the outstanding superiority of melamine-formaldehyde impregnated fillers explained by the known relatively slight superiority of, melamine-formaldehyde resin overthe other resins. 1 5 Q; The improvement in'strength and waterresistance may be demonstrated also by testing [a molding composition embodying the invention made by impregnating a "filler consisting of coarsely chopped-cotton cloth as hereinbefore described-with a solution of a melamine-formaldehyde reaction product. The impregnated cloth is dried and cured in an oven for 4 hours at 180 F. A polymerizable polyesteris prepared by the procedure hereinbefore described from a charge consistingof 1.5 mols of maleic anhydride, 1.5 mols of diethylene glycol and'an amount of hydroquinone equal tov 0.2 percent of the charge.- The charge is heated to a temperature of 210 C. and is held at this tempera- 2. V ture for 6% hours. The resulting polyester 75 TABLE 3 Percent 'Percnt Flexural Deflect Compress 1m act Biol T eof Filler Concl. Ground iller' p Hardyp Product in Comp Strength Strength Strength. Strength Hess 10 1 Yes 10, 350 0.007 29, 075 0.52 40 20 Yes 55 9, 310 0. 084 24, 000 0. 25 40 Yes 55 1a, 440 o. 140 37, 400 o. 35 47 05 Yes 55 9, 580 0. 11s 28, 000 o. 23 4s. 0 No 55 8, 800 0. 071 27, 100 0. a5 40 20 No I 55 10,080 0.085 ,000 TABLE 4 parts), which has an acid number of about 1.1, is cooled and is dissolved in acetone (100 parts) Pevpent Patent Absin Abs in with diallyl phthalate (25 parts) and benzoyl Type ffiller 055d, Groun Ffi1 i 2 3 9%; peroxide (2 parts). The dried 1mpregnated filler Product Cmnp- 1 day 7 days 1 is incorporated with the polyester by soaking the filler (40 parts) in the acetone solution of the earrin 10 Yes 55 0.275 0.04 polyester (120 parts). The acetone is removed B $2: 3& by drying overnight at. room temperature inQa D01 05 Yes 55 0.05 0.14 circulating oven and the resulting composition g:: 8 1 31 (type I) is compression molded to produce ar- 0 1 N0 55 0-165 50,505 ticles of dimension suitable for physical testing.

Also, a polymerizable polyester is'prepared bythe for 6 more hours. 85 parts), which has an acid number of about hydroquinone-equal to 0.04 per cent of the charge.

' Thecharge is heated to 220 C. (over a period of 2 hours) and is held between 220 and 226 The resulting polyester 35, is cooled to 145-150 F. and is thoroughly mixed with diallyl phthalate (15 parts) and a paste ofbenzoyl peroxide (1 parts) and'tricresyl phosphate (1 parts) to form a solution.

' The impregnated cellulosic filler, the polymerizable polyester solution and, as a lubricant, an

amount of zinc stearatee um t 1 per cent of the composition are then milled on a heated two-roll (differential speed) rubber mill. The

time of milling is determined by testing the molding material every minute during milling ical testing. The composition is fast curing and gives'moldings free from gas.

Table shows the properties of articles so preparedand more specifically describes the compositionsfrom which the articles are molded by specifying the per cent of melamine-formaldehyde condensation product in the dried impreginated cloth (line 1), the type of composition (line 2), and the length of time on the rolls in minutes if milling is used (line 3).

The water absorption (in per cent by weight of the test piece) is given for tests in which test piecesmade from various molding compositions are immersed in cold water for 1 day (line 4), '10 days (line 5) and 30 days (line 6). I

Flexural strength and elastic modulus (in flexme) are obtained from atest piece /8x 1"x 2") in the manner hereinbefore described. The

fiexural strengths are given for the test pieces when dry (line 7) and after being immersed in cold Water for'30 days (line 8). Also, the

elastic moduli are given for test pieces when dry (line-9) and after'being immersed in cold Water for 30 days (line 10). For the sake of compari- 'son, test results for control pieces, i. e., pieces fin which" the reaction product is omitted from "thecellulosic filler, are included in 'Table 5.

5 30 days areas much as 100 per cent greater than the control pieces. The general appearance of the piecesembodying the invention is noticeably superior to that of the control pieces after 10 days immersion in water, at which time the polyester and cloth fibers show signs of separating in the control pieces.

In the production of laminates embodying the invention the coating of thedried impregnated cell-ulosic laminating material with the polymerizable polyester may be carried out by any of the known methods. Generally, it is preferable to dip the cellulosic laminating material in a solution of the polymerizable polyester in a volatile solvent and air dry the laminate for several hours before curing under'pressure. Also, the polyester or a solution of the polyester may be brushed or sprayed onto the cellulosic laminating cloth or paper.

The proportion of the polyester binder in the laminate may range from the minimum that is capable of binding the sheets of cellulosic laminating material, for example, about 20 per cent of the laminate, to the maximum that is capable of producing by ordinary laminating procedures a product having the usual laminate characteristic's, for example, about 75 per cent of the laminate. The preferred range in which the best properties are obtained is about 35 to about per cent of the laminate. The particular percentages at which the best results are obtained depend to a great extent upon the type of laminating material and the specific use of the resuiting product. Laminates containing about 50 per cent polyester usually have the best allaround combination of desirable properties.

The improvement in strength and water resistance may be demonstrated by testing a laminate embodying the invention made by impregnating a white laminating paper with a commercial water-soluble melamine-formaldehyde condensation product (Melamac402), the laminatingpaper being cut into strips, immersed in an aqueous solution of the melamine-formaldehyde condensation product containing an amount of butanol equal to 5 per cent of the Water in the solution, and then dried by exposing to the atmosphere for 24 hours. The dried impregnated strips may be coated with the polyester binder at once, i. e. uncured, or after being heated for TABLE 5 Sample Number control Control A B CcntroI- C D (1) Percent Melamine-Formaldehyde in Dry Filler 0 0 10 30 0 10 3O (2) Type of Composition II II II II I I I (3) Time on Rolls (min) 7 l2. 5 5. 3. 5 (4) Water Absorption (1 day) 2. 1 2.4 1.4 .89 1. 63 1.08 .70 (5) Water Absorption (10 days) 6. 4 6. 9 5. 4 2. 3 5, 2 4. 8 2. 1 (6) Water Absorption (30 days) 6. 6 7. 3 6. 2 3. 5 6. 6 5. 4 3. 3 (7) Flexural Str. (dry) 9, 900 11,400 12, 800 12, 900 8, 750 9, 920 9, 450 (8) Flexural Str. (30 days im- I mersion) 5, 5,- 8, G00 10, 500 (0) ElasticM'od. (dry) l0-) 0.75 0:33 10 1.2 0.94 1.1 1.06

.'(10) Elastic Mod. (30 days immersi0n) l0-) 0.38 O. 41 0. 91 0.92

From Table 5 it can be seen that the control much water in 1 day, .up to 3 times as much water in 10 days and up to 2 times as much water in 30 days as the-pieces embodying the invention.

" The fiexuralstren'gths of the pieces embodying "the invention when dry are as much as 30 per cent greater and after immersion in water for 75 and benzoyl peroxide (5' parts), and then are air pieces in cold water absorb up to 2 times as 15 minutes at 300 F. to convert the condensation product to a substantially infusible state, i. e., cured. The strips (cured or uncured) are dipped in a 50 per cent acetone solution of a polymerizable polyester (produced as described hereinbef-ore) which contains diethylene glycolmaleate (75 parts), diallyl phthalate (25 parts) dried for 24 hours. The dried 0015mm stacked under a pressure of 400 pounds per square inch and cured for 20 minutes at 212 F. and then for 22 'pieces" W x 1'' 2") of the resulting'laminates are as follows:

20 minutes at 300 F. to produce laminates which show no defects and are free from gas. 1 -5 g if fi g Table 6 shows the properties of laminates so Controls Solution'gf prepared, and more specifically describes the g ggfjf compositions from which the laminates are produced by specifying the per cent of the melaminememe! Strength (dr up 19, 19 960 formaldehyde condensatmn product in the im- 10 rlexural strength (after immersion for pregnatingsolution (001.1), and the per cent of fif gfi t' g 'z gg g gga a; 17,100 24,290 the melamine-formaldehyde condensation proddays 11,300 21,800 not in the dried impregnated paper (col. 2) and by "figfij tg ggg gg ggg g 124x10 9 specifying whether the impregnated paper is cured 24 hour .a0 10 1. 50x10 uncured 01. e compressive strength rasers-.tffrfi siiifif. em 5 We test for test pieces x /2" x of the l g laminates is carried out in the same manner as I l the compressive strength test for molded articles. From these data i can be e that, although The compressive strength is given in pounds per the laminates embodying the n e t o are not square inch for laminates which are dry (col. 4), appreciably Superior in flexlllel Strength When are i e in cold water fo 24 hours (001, 5 dry, these laminates actually have greater flexand. are immersed in cold water for 10 days (001. 11ml Strength and are twice as strong a the 7 A150, the per cent decrease in compressive control laminates after 10 days immersion in 1 trength (on a dry strength basis) is given for water. The reason for the increase in strength I the laminates after immersion in cold water for 25 i not understood although repeated tests indicate 24 hours (col. 6) and after immersion in'cold "t it is reel- The us o e laminates water for 10 days (col. 8). For the sake of comembodying the invention When dry is about 3.0 pari'son, properties of control laminates, i. e., per cent reater than that of the control lamilaminates in which the reaction product is nates, but after 10 days immersion in water the omitted from the paper laminating material, are laminates embodying the invention have moduli shown in Table 6. as much as 5 times as great as that of the con- TABLE 6 Percent i ggggfig' og tl r i s a- Uncured gggg Percent Percent in treating tion Prod. or Cured Dry lday's Decrease 10 days Decrease solution 011 paper 11111119131011 immerslon 0 0 20,200 8,900 40 0, 000 00 1 Uncured 21,000 11,1100- 44 8,400 00 1 Cured 20, 500 11, 400 44 7, 590 or 2.5 Uncured 21,000 15, 300 30 12, 400 43 2.5 Cured 20,200 12, 900 a0v ,790 57 5 Uncured 23,400 18,700 20 11,400 51 0 Cured 24, 200 20, 300 15 12, 000 10 Uncured 31,000 28. 500 10 22,200 30 10 Cured 23,700 25, 700 10 18,900 at 20 Uneured 21,200 20,200 4 ,500 25 20 Cured 20,000 24, 400 8 23,400 12 From Table 6it can be seen that laminatesemtrol laminates. In other words, upon 10 days .bodying the invention increase in compressive 55 immersion in water the moduli decreased82 strength (whenv dry) with increases in the conper cent in the control laminates as compared ,centration of the condensation product in the to only 7 per cent in the laminates embodying impregnating solution up to 10 per cent, at which the invention. The loss in modulus indicates a maximum of 55 per cent improvement over the 0 that the bond fails between thefiber of the paper control laminates is reached. The compressive and the polyester in the control laminates. The ,strength of laminates embodying the invention results of these tests show that laminates emshows a much greater improvement over the conbodying the invention compare favorably with trol laminates after immersion in cold water. glass th nates a d may be used satis- For example, at the end of 10 days immersion in factorily unde ex y Wet or humid condicold water, the laminates of the invention are as tions. much as 3.2 times as strong as the control lami- The improvement in strength and water -renates and the decrease in compressive strength of sistance may be demonstrated also by, test the control laminates is as much as 5 /2 times as aminates embodylng' invention made y mgreat pregnating heavy muslin and light airplane cloth 0 A procedure is carried out that is the same as with a solution of a melamin -f r hy e c0n that described above for the production of the densation pr u prepared as hereinbeforedepaper laminates except t t t dried initially scribed. The cloth is washed with a sulfonated impregnated strips are cured for one-half hour soap to remove the size, dried and then ironed. at 248 F. instead of 15 minutes at 300 F. The .The washed clothiscut into strips, soakedfor 5 flexural strengths andv elastic moduli of test Z .minutes in alt-20 per cent aqueou solution of a melamine formaldehyde condensation product duces the moduli of the control laminates about 50 per cent in contrast to reductions as low as 20 per cent for laminates of the invention.

It is to be understood that the properties of solution of a polymerizable polyester produced cloth laminates are dependent to a great extent as described hereinbefore which contains diupon such factors in the cloth itself as fiber thyl n e y l-mal at ('75 p d allyl length, thread size, thread twist, fiber condi- .phthalate (25 parts), and benzoyl peroxide (5 tioning, surface treatment and weave. Howparts), air dried for 24 hours, and laminated into ever, the effect of other factors such as the panels (9" x 12" x by the procedure heremethods of impregnation and of removal of exinbefore described. cess impregnating solutionmay be shown in the Table 7 shows the properties of test specimens preparation of a muslin laminate. The muslin cut'from panels so prepared, and more specifically cloth is cut into strips about six feet long and six describes the production of the laminates by inches wide, washed in sulfcnated soaps and specifying the type of cloth used, i. e., muslin'or rinsed in tap water to remove some of the size airplanecloth (line 1), the number of plies in and dried. (This procedure causes a loss of 10 the laminate (line 2), the percent of melamineper cent of the original Weight of the cloth.) formaldehyde condensation product in the dried The strips are soaked for minutes at 65 C. impregnated cloth (line 3) andthe per cent'of in a solution of a commercial water-soluble polyesterbinder in the laminate (line 4). The 20 melamine-formaldehyde condensation product 'amount of water absorbed in the water absorp- (Melamac 502) in Water containing an amount 'tion test is given in per cent by weight of the of butanol equal to 5 per cent of the water. test piece for pieces immersed in cold water for After soaking 20 minutes in the solution, part 3 days (line 5), 10 days (111186) and 30 days (line of the strips are put through rin e part '7). The compressive strength is given for test are washed in cold water and the rest are pieces which are dry (line 8), have been imwashed in hot water. The strips are air dried, mersed in cold Water for 10 days (line 9) and have cured by heating for 1 hour at 120 C., dipped been immersed in cold water for days (line in a per cent acetone solution of a polyester 10). Theelastic moduli are given for test pieces binder of the class described hereinbefore conwhich are dry (line 11),'have been immersed in 30 taining diethylene glycol-maleate (75 parts), water for 30 days (line 12), and have been imdiallyl phthalate (25 parts) and benzoyl peroxmersed in Water for 30 days and subsequently reide (5 parts), and air dried for 24 hours. The dried (line 13). dried strips are stacked under 400 pounds per TABLE 7 1. 010m type Muslin ig; g Muslin. 5,

2. N0. Plies in 15151115145-.. 12 1s 12 18 12 18 3. Percent Condensation Prod.

incloth 0 0 20 20 14 12 4. Percent Polyester in laminate 61 01 55 55 55 5. Water Absorption,3days 2.80 3.00 1.50 1.11 2.02 1.28 5. Water Absorption, 10 days. 4.68 5.00 2.40 1.05 3.18 3.00 7. Water Absorption, 30 days... 5.85 5.80 4.07 3.12 4.80 3.52 s. Compressive Strength (dry) 17,700 15, 000 17,200 15,400 15,500 15,300 9. Compressive Strength (immersed 10 days) 13,400 12,800 10,400 14,100 14,700 14,000 10. Compressive Strength (im- 7.

mersed 30 days) 14,300 12,800 17,400 10,200 10,700 15,200 11. Elastic Mod. (dry) (xiii- 7.1 11.0 8.15 12.3 8.3 9.40 12. Elastic Mod. (immersed 30 days) (X10-5) 3.8 5.0 5. 95 6.04 0.55 0. 70 13. Elastic Mod. (immersed 30 days, dried) 10 3.5 6.5 5.0 5.0. 5.35 7.00

From Table '7 it can be seen that the results square inch pressure and cured for 20 minutes obtained depend to a great. extent upon. the at2l0 F. and. then for 20 minutes at 300 F.

'typeof cloth that is used in the laminate. For 'Table 8 shows the properties of test pieces example, in 10 days immersion the laminates 55 cut from la i t 0 prepared and more embodying the invention absorb about 50 per cifically describes the production of the lamcent less than control laminates, but in longer inates by specifying the per cent of melamine- D O s Of m u as 30 ays, the usl formaldehyde condensation product in the imlaminates of the invention absorb about 30 per pregnating ol ti (li 2) t eth e cent less than the control lam nates while the ployed in removing the excess impregnating airplane cloth laminates of the invention absorb solution, e wringing Washing with hot water abort 85 per cent lesstthantirilhi 04137111 5121 i m' s or washing With cold Water (line 3), the per n e 90111211955918 5 es e m es cent of melamine-formaldehyde condensation embodying the invention are not appreclably product in the dried im re flat d 1 th 4) better than the control laminates whendry, but and the er 0 t f 1 p 9 me after 10 days immersion in water the control n: t p p0 yes er mder m thelaml' laminates have decreased as much as 30 per cent 8 me he 9 absorbed while the laminates of the invention have dethwater absorptloniest 1S glYen 1n per cent creased only about 5 or 10 per cent in strength. P Welght of the test P199? for Pleces immersed The compressive strength of the laminates emm cold for 1 day (1111B 4 ys (line bodying the invention after 30 days immersion 10 days (11I1e 3) and 30 days (line 9). The is in generalgreater than the dry strength. The COIPPFBSSIVB e h s v n for est p c elastic moduli of the laminates of the invention h c are y (line 10), have been immersed are about 20 per cent greater than those of the in'cold water for 1 day (line 11) and have been -contro1 laminates,- and immersion in water re- 7 immersed in cold water for 10 days (line 12).

sample N I Percent Qond. product in impregnating so Method of removing excess impregnating sol Percent Cond. product in dried cloth. Percent Polyesterin laminate..- Percent Water absorp. in 1 day Percent Water 'absorp. in 4 days. Percent Water absorp. in days Percent Water absorp. in 30 days Compress. Strength (d Compress; Strength (immersed for l comma 16, sec

ay Compress. Strength (immersed ior'lO days) g be: outlawork 1 Wash in cold water. i 1 Wash in hot water.

8 Wring;

From Tables it can be Seen that the control e beater: type mixer with the solution of the urea-formaldehyde condensation product diluted laminates absorb about 2 to 3 times as much water .as the laminates of the invention during an equal period of immersion. The compressive from the cloth. cause considerable variation in the percent of melamine-formaldehyde condensation product leftin the cloth and to a certain extent cause other unexplained variations in the water absorption and compressive strength.

For example, the cloth samples subjected to a 'per cent solution impregnationand subsequent rinsing, inv cold'water (line 4, Table 8), those subjected .to a 50 per centsolutionimpregnation and subsequent hot water rinsing (line 5,

Table 8) and those subjected to a .10 per cent solution impregnation and. subsequentwringing out (lined, Tablet 8) have a nearly equal amount of the condensation product left ,in the cloth, I

but the cloth subjected to the cold water rinse produces a laminate which has noticeably better waterresistance and compressive strength. Al-

though the ;reason for this is not understood completely it is believed that a procedure such as the, cold water rinse has the effect of leaving the condensation product mainly inside the fibers and that such efiect' is responsible in part for the superiorproperties of the'laminate;

VThe appearance of the laminates of the invention after immersion for 10 days is appar- 1 ently unchanged in that they do not show any appreciable swelling, but the-controllaminates show a noticeable swelling and a breaking away of the polyester from the surface of the cloth. Also, laminates of the invention are lesssensitive parts of a solution of '1 mol of adipoguanamine and an amount of formalin containing 5 mols] to high temperatures in thatthey do nottend to yellow at 300 F. as do the controllaminates,

andare much less 'afiectedjby' cigarette burns than are the control laminates.

' l Example 1',

Y A solutionof '2 mols ofurea in formalin .(31

per: cent aqueous formaldehyde solution) containin'ga 3 mols of formaldehyde is held at 30 C. i and at a pH of about 7' for 6 hours. Anamount' of alphaTcellulose' fluff equal to the weight of urea;

is completely impregnated by mixing it in an with suflicient Water so that the weight of the diluted solution is from 2 to 3 times the weight of the cellulosic filler. The impregnated filler is thoroughly dried and then ground with l per cent of its weight of maleic anhydride and is held Then the impregnated filler, about half its weight of a polymerizable 1 polyester prepared as described hereinbefore and I an amount of zinc stearate equal to about 2 per cent of the composition are milled for 10 at 212 F. for two days.

to- 12 minutes on a heated 2-roll (difierential speed) rubber mill at the lowest temperature at which a homogenous mass can be obtained. The resulting composition is removed in sheets, is

allowed to solidify fully while at about to .F. and is granulated in a highv speed cutter to a maximum particle diameter of about inch. The granulated composition is compression molded at a temperature equivalent to 65 to '70 pounds gauge" pressure of steam for 1 to 5 min- The composition is fast curing and gives moldings free from gas which have excellent utes.

strength and water resistance.

Example 2 A procedure is carried out that is the same as that given in Example 1 except that parts of the cellulosic filler is impregnated with parts i of a hot 20% solution of a condensation product obtained by holding a solution of 1 mol of melamine in formalin containing 3 mols of formaldehyde at 80 C. for 10 minutes at a pH of 7.

The resulting composition is fast curing and gives i moldings free from gas which have substantially greater strength and water resistance than those of Example 1.

' Example 3 A procedure is carried out that is the same as 3 that given in Example 1 except that 100 parts of the cellulosic filler is impregnated with 250 of formaldehyde in sufiicient methyl Cellosolve to give a 10% solution of the condensation product, which hasbeen held at 100 C. for 20 min ut'esat a pH of 7. The resulting composition; is fast curing and gives moldings free from "gasj whose strength'and water resistance are very; high; but not as high as in the case ofthe molded articles of Example 2; V

. Example 4 A procedure is carried outthat is the same. as that given in Example 1 except that 100; p rts? .1

Example A procedure is carried out that is the same as that given in Example 1 except that 100 parts of the cellulosic filler is impregnated with 125 parts of a 20% solution of a condensation product obtained by holding a solution of 1 mol of propylene diurea in formalin containing 2 mols of formaldehyde at 80 C. for minutes at a pH of '7. The resulting composition is fast curing and gives moldings whose. properties aresubstantially the same as thoseof the moldings of lilxample 1.

Example 6 Strips of cellulosic cloth or paper laminating material are impregnated with 20 per cent of their weight .of a condensation product, using an impregnating solution prepared as described in any of the previous examples. Any xcess condensation product in the strips is removed by putting the strips through a wringer or by wash-l ing.them in hot or in cold water. The strips are air dried and the condensation product then is converted to the substantially infusible state by heating. to 250 F. for 10 minutes. The dried impregnated strips are immersed in a 50, per cent acetone solution of a polyester binder prepared as described hereinbefore. Th strips. are dried in a circulating oven at room temperature for 24 hours, stacked to form the desired number of plies, and cured under 400 pounds per square inch pressure for ZOminutes at 210 F. and then for 20 minutes at 300 F. The resulting laminates are free from gas and have excellent strength and water resistance.

Having described the invention, I claim:

1. A material which upon polymerization has improved strength and water resistance, comprising 100 parts of a polymerizable olefinically unsaturated polyhydric alcohol-'polycarboxylic acid polyester and froml to 400 parts of a material consisting substantially of finely divided cellulose impregnated with from- ,4 to 10 times itsweight of an infusible reaction product of formaldehyde 3. A material of improved strength and water resistance, comprising the product of the polymerization of a material claimed in claim 1 4. Amaterial of improved strength and water 1 in' which;

resistance, comprising the product of the poly- 28 6. A method of producing a material which upon polymerization has improved strength and water resistance that comprises impregnating material consisting substantially of finely divided cellulose with from to ten times i-ts 'weight of a thermosetting reaction product of formaldehyde and a substance of the class consisting of urea and melamine, converting the reaction product to its infusible state, and then impregnating from 1 to 400 parts of the material with parts of a polymerizable olefinically unsaturated polyhydric alcohol-polycarboxylic acidpolyester.

7. A process which comprises uniformly impregnating a finely divided natural cellulosic filler with a 1% to 20% aqueous solution of a methylol urea from the class consisting of monomethylol urea, dimethylol urea and mixtures of monomethylol urea and dimethylolurea, retaining an amount of said solution equivalent to 5% to 15% of methylol urea based on the weight of said filler, thoroughly drying said impregnated I filler, converting said methylol urea tothe infusible stage, then incorporating the resultant impregnated cellulose filler in a, copolymerizable mixture of styrene and an olefinically unsaturated, vulcanizable, linearalkyd resin and finally molding and vulcanizing the mixture of styrene and said alkyd resin containing said impregnated converting said methylol urea to th infusible stage, then incorporating the resultant impregnated cellulose filler in a copolymerizable mixture of an olefinically unsaturated, vulcanizable, linear alkyd resin and a polymerizable olefinically unsaturated monomeric compound compatible therewith, and finally molding and vulcanizing said copolymerizable mixture containing said impregnated filler.

9. A process which comprises uniformly impregnating a finely divided natural cellulosic filler with a 1% to 20% aqueous solution of a methylol urea from the class consisting of monomethylol urea, dimethylol urea and mixtures of monomethylol urea and dimethylolurea, retaining an amount of said solution equivalent to 5% to 15% of methylol urea based on the weight of said filler, thoroughly drying said impregnated filler, converting said methylol urea to the infusiblestage, then incorporating the resultant impregnated cellulose filler in a copolymerizable mixture of an olefinically unsaturated, vulcanizable, linear alkyd resin and a polymerizable olefinically unsaturated monomeric compound compatible therewith, and finally molding and vulcanizing said copolymerizable mixture containing said impregnated filler.

10. A process which comprises uniformly impregnating a finely divided natural cellulosic filler with a 1% to 20% aqueous solution of a methylol urea from the class consisting of monomethylol urea, dimethylol urea and mixtures of monomethylol urea and dimethylolurea, retain-.

ing an amount of said solution equivalent to 10% of methylol urea based on the weight of saidfiller, thoroughly dryingsaid impregnated filler, converting said methylol .urea in the vinfusibla:

29 stage, then incorporating the resultant impregnated cellulose filler in a copolymerizable mixture of styrene and an olefinically unsaturated,

ARTHUR M. HOWALD.

REFERENCES CITED The following references are of record in the file of this patent:

3o UNITED STATES PATENTS Number Name Date 2,197,357 Widmer Apr. 16, 1940 2,255,313 Ellis Sept. 9, 1941 2,288,279 Hopfi June 30, 1942 2,368,451 DAlelio Jan. 30, 1945 FOREIGN PATENTS Number Country Date 412,373 Canada. May 11, 1945 OTHER REFERENCES Modern Plastics Encyclopedia (1946), pages 158-159, 338-343. 

1. A MATERIAL WHICH UPON POLYMERIZATION HAS IMPROVED STRENGTH AND WATER RESISTANCE, COMPRISING 100 PARTS OF A POLYMERIZABLE OLEFINICALLY UNSATURATED POLYHYDRIC ALCOHOL-POLYCARBOXYLIC ACID POLYESTER AND FROM 1 TO 400 PARTS OF A MATERIAL CONSISTING SUBSTANTIALLY OF FINELY DIVIDED CELLULOSE IMPREGNATED WITH FROM 1/200 TO 10 TIMES ITS WEIGHT OF AN INFUSBLE REACTION PRODUCT OF FORMALDEHYDE AND A SUBSTANCE OF THE CLASS CONSISTING OF UREA AND MELAMINE. 